The aviation industry is at a critical crossroad, facing increasing pressure to reduce its environmental impact while managing rising operational costs. As a significant contributor to global CO2 emissions, the sector must find innovative solutions to balance sustainability with economic challenges. However, strict regulations, high material costs, and fragmented supply chains complicate efforts to drive change. This project explores how the Circular Cabin model—a framework for recycling and reusing cabin interior parts to reduce waste and extend material lifecycles—could be integrated into KLM Royal Dutch Airlines' Maintenance, Repair, and Overhaul (MRO) operations.

Cabin interior parts, particularly seats, were identified as high-potential areas for circularity due to their frequent replacement and material composition. A pilot study on seat backrests demonstrated that recycled polycarbonate can meet stringent aviation fire safety certification, representing a major milestone in advancing circular cabin practices. This breakthrough paves the way for further testing and offers a practical approach to scaling recycling practices within aviation.

To translate these findings into actionable steps, a playbook was developed to guide KLM E&M employees in embedding circularity into their operations. The playbook includes tools such as a decision tree for assessing recycling potential, a strategic roadmap for implementation, and focus areas for further research. By connecting strategic vision with practical application, the playbook provides a clear pathway for operationalizing circularity within KLM Engineering & Maintenace’s (E&M) operation.

This project highlights the transformative potential of circularity in aviation. By adopting circular practices, KLM E&M can reduce material costs, enhance supply chain resilience, and create a more level playing field with Original Equipment Manufacturers (OEMs). With a commitment to the tools and insights developed in this project, KLM E&M has the opportunity to become a frontrunner in sustainable innovation, setting a powerful precedent for the industry and redefining the role of aviation in shaping a sustainable future.